Turbine engine component with vibration damping

ABSTRACT

A vibration resistant fan guide vane for a gas turbine engine is provided. The fan guide vane comprises a vibration damping component made of a MAXMET composite. The damping component may be a cover that covers some or all of the fan guide vane body. Alternatively, portions of the fan guide vane body or the entire vane body may be made from MAXMET composites. The disclosure makes use of the ultrahigh, fully reversible, non-linear elastic hysteresis behavior that MAXMET composites exhibit during cyclic elastic deformation in order to damp vibration.

CROSS-REFERENCE TO RELATED APPLICATION

This Application is a continuation of allowed U.S. application Ser. No.14/763,001 filed Jul. 23, 2015, which has issued as U.S. Pat. No.10,167,733. U.S. non-provisional application Ser. No. 14/763,001 was aUS National Stage application under 35 USC § 371 of International PatentApplication No. PCT/US2013/075359 filed on Dec. 16, 2013, and claimspriority under 35 USC§ 119(e) to U.S. Provisional Patent ApplicationSer. No. 61/790,006 filed on Mar. 15, 2013 and 61/881,689 filed Sep. 24,2013.

FIELD OF THE DISCLOSURE

The subject matter of the present disclosure relates generally tovibration damping in turbine engine components. More particularly, thepresent disclosure relates to a turbine engine component such as a fanguide vane comprising a vibration damping component made of a “MAXMET”composite.

BACKGROUND OF THE DISCLOSURE

Gas turbine engines, such as those used on jet aircraft, generallycomprise an air intake port, a fan mounted on a hub near the air intakeport and surrounded by a fan case, a low pressure compressor (LPC)section, an intermediate section aft of the LPC section, a high pressurecompressor (HPC) section, a combustion chamber or combustor, high andlow pressure turbines that provide rotational power to the compressorblades and fan respectively, and an exhaust outlet. The fan and LPCsection may be operably connected to the low pressure turbine by aninner drive shaft which rotates about an engine center axis. A cone-likespinner may be mounted over the hub forward the fan blades to help guideair flow.

Some sections of the engine include airfoil assemblies comprisingairfoils (typically blades or vanes) mounted at one or both ends to anannular endwall. Included among these sections is the fan section inwhich fan guide vanes help direct air coming off the fan.

Modem gas turbine engines employ very high air velocities and workingtemperatures in order to increase engine operating efficiency. Hollowaluminum fan guide vanes and other structures exposed to these high airvelocities and temperatures can vibrate, which can pose a risk of damagedue to metal fatigue.

The present disclosure addresses this problem.

SUMMARY OF THE DISCLOSURE

In one aspect of the disclosure a turbine engine component such as a fanguide vane is provided. The turbine engine component comprises a bodyand a damping cover. The damping cover comprises a “MAXMET” compositeand covers part of or all of the body.

The MAXMET composite is a composite material comprising a MAX phasematerial and a metal component. The MAXMET composite may be compatiblewith aluminum. The MAX phase material comprises MAX phase particleshaving a crystalline nanolaminated structure and the metal component isa metal matrix. The MAX phase particles may be embedded in the metalmatrix.

The MAX phase material may have the formula Mn+1AXn, wherein: M is atransition metal; A is an A-group element; X is carbon (C), nitrogen (N)or both; and n=1 to 3. The MAX phase material may be one of over sixtydifferent compounds, including but not limited to ThAlC, Cr2AlC, Ta2AlC,ThAlN and Ti4AlN3.

The metal component may comprise a hexagonal closed packed metal. Thehexagonal closed packed metal may be Magnesium, Titanium, Cobalt, Zincand Zirconium.

The MAX phase material may define a plurality of pores, and the metalcomponent may occupy at least some of the pores.

The MAX phase particles may be bonded to the metal matrix by chemical ormetallurgical bonding.

The fan guide vane may have a body that is airfoil shaped, wherein thebody has a first side and an opposite side, and both the first side andthe opposite side extend between a leading edge and a trailing edge. Thebody may define areas or pockets covered by a damping cover.

In another aspect of the disclosure a method of making a vibrationresistant fan guide vane is provided. The method may comprise the stepsof: Making a preform comprising a MAX phase material, the preformdefining a plurality of pores; Submerging the preform into a bath of amolten metal, allowing the molten metal to infiltrate into the pores toachieve a cover; and Bonding the cover to the body. The cover may bebonded to the body by metallurgical or adhesive bonding or mechanicallyfastening.

In another aspect of the disclosure a vibration resistant fan guide vaneis provided. The fan guide vane comprises a body and a MAXMET compositewithin the body. The MAXMET composite may be incorporated into theentire body or less than the entire body. The body may be made primarilyof aluminum.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the concepts of the present disclosurerecited herein may be understood in detail, a more detailed descriptionis provided with reference to the embodiments illustrated in theaccompanying drawings. It is to be noted, however, that the accompanyingdrawings illustrate only certain embodiments and are therefore not to beconsidered limiting of the scope of the disclosure, for the concepts ofthe present disclosure may admit to other equally effective embodiments.Moreover, the drawings are not necessarily to scale, emphasis generallybeing placed upon illustrating the principles of certain embodiments.

Thus, for further understanding of these concepts and embodiments,reference may be made to the following detailed description, read inconnection with the drawings in which:

FIG. 1 is a longitudinal cross-sectional view of a gas turbine engine inwhich fan guide vanes according to the present disclosure might be used;

FIG. 2 is an enlarged view of a portion of the gas turbine engine ofFIG. 1; and

FIG. 3 is a perspective view of a fan guide vane according to thepresent disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

In the disclosure that follows certain relative positional terms areused such as “forward”, “aft”, “upper”, “lower”, “above”, “below”,“inner”, “outer” and the like. These terms are used with reference tothe normal operational attitude of a jet engine and should not beconsidered otherwise limiting. The forward end of a jet engine generallyrefers to the air intake port end and the aft end generally refers tothe exhaust end. Also, “radially outward” generally refers to adirection away from the engine center axis while “radially inward”refers to a direction toward the engine center axis. Finally, althoughthe following disclosure discloses a fan guide vane having a vibrationdamping component made of a MAXMET composite, it should be understoodthat the vibration damping component may be used with other turbineengine components.

FIG. 1 is a longitudinal sectional view of an exemplary turbofan jetengine 10 that may be equipped with fan guide vanes according to thepresent disclosure. The engine 10 comprises an air intake port 12, fanblades 14 mounted on a hub near the air intake port 12 and surrounded bya fan case 18 which is mounted within an engine housing or nacelle (notshown), a low pressure compressor (LPC) section 20, a bearing supportsection 22 aft of the LPC section 20, a high pressure compressor (HPC)section 24, a combustion chamber or combustor 26, high and low pressureturbines 28, 30 that provide rotational power to the HPC blades and LPCand fan blades 14 respectively, and an exhaust outlet 32, all centeredaround an engine axis (A). A substantially conical spinner 16 (cap andbody) is mounted over the hub forward the fan blades 14 to help guideair flow.

FIG. 2 is an enlarged view of a portion of the gas turbine engine ofFIG. 1. Fan guide vanes 34 may be mounted to and extend between a corenacelle 36 and the fan case 18 to guide air coming off the fan blades 14through a fan duct 38, bypassing the engine core. The core nacelle 36and the fan case 18 are generally annular and concentric about theengine axis A. The fan guide vanes 34 are circumferentially spacedapart, thereby defining a plurality of fluid flow passages betweenadjacent vanes 34.

FIG. 3 is a cross-sectional view of a fan guide vane 34 taken along line3-3 of FIG. 2. Each fan guide vane 34 may comprise an airfoil shapedbody 40 having a first side 42 such as a pressure side and an oppositeside 44 such as a suction side, both sides 42, 44 extending between aleading edge 46 and a trailing edge 48. Airflow moves through the fluidflow passages from a location forward the leading edges 46 of the fanguide vanes 34 and toward the trailing edges 48 as the engine 10typically operates. Each fan guide vane 34 may define a hollow interior50.

In accordance with the present disclosure, the fan guide vanes 34 mayfurther comprise a vibration damping component made of a MAXMETcomposite. The damping component may be one or more covers 52 that coversome or all of the fan guide vane body 40. The cover(s) may be in theform of overlay panels or substitution panels. Alternatively, portionsof the fan guide vane body 40 or the entire fan guide vane body 40 maybe made from a MAXMET composite. The disclosure makes use of theultrahigh, fully reversible, non-linear elastic hysteresis behavior thatMAXMET composites exhibit during cyclic elastic deformation in order todamp engine part vibration.

A MAXMET composite is a composite material comprising a MAX phasematerial and a metal phase. In a typical MAXMET composite, the MAX phasematerial comprises graphite-like particles (MAX phase particles) and themetal phase is a metal matrix. The MAX phase particles may be embeddedin the metal matrix. By embedding the MAX phase particles within a metalmatrix, loads and forces can be transferred between the MAX phaseparticles and the metal matrix.

The MAX phase material is a high modulus and high damage tolerantmaterial. The MAX phase material may be in the form of a powder orparticles having a crystalline nanolaminated structure. As disclosed inU.S. Patent Publication No. US 2010/0055492, incorporated herein byreference, the MAX phase material typically has the formula Mn+1AXn,where M is a transition metal, A is an A-group element, X is carbon (C),nitrogen (N) or both, and n=1-3. The transition metals include thed-block elements (including, for example, Titanium, Chromium andTantalum). The A-Group elements include the alkaline earth elements(Beryllium, Magnesium, Calcium, Strontium, Barium and Radium), the GroupIIiA elements (Boron, Aluminum, Gallium, Indium and Titanium) and theGroup IVA elements (Carbon, Silicon, Germanium, Tin and Lead).

Some examples of MAX phase materials are ThAlC, Cr2AlC, Ta2AlC, ThAlNand Ti4AlN3. Over sixty other examples of MAX phase materials exist.

The metal component provides a strong, readily handled medium, such as ametal matrix, for the MAX phase particles. The metal matrix componentmay comprise a low, medium or high melting point metal, and providesductility and toughness to the overall MAXMET. The metal matrixcomponent may comprise a hexagonal closed packed metal like Magnesium,Titanium, Cobalt, Zinc and Zirconium or other metal like Aluminum andNickel.

In the MAXMET composite, the MAX phase material may define a pluralityof pores, and the metal component may occupy at least some of the pores.The MAX phase particles may be bonded to the metal matrix by chemical ormetallurgical bonding. An example of a MAXMET composite is Mg—ThAlC.Mg—ThAlC has a total composite density of about 2.8 glee and iscompatible with aluminum, so it can be used as a damping agent for analuminum fan guide vane or other aluminum structure.

The properties of MAXMET composites render them good candidates asdamping materials for structural articles such as fan guide vanes. MaxPhase materials, due to their nano-laminated structure and their uniquedeformation mechanism under load, absorb mechanical energy which thendissipates during deformation, thereby damping the movement or vibrationof the structural article. Adding a metal phase to the MAX phasematerial can increase this damping capacity by almost one order ofmagnitude.

MAXMET composites possess a number of properties found in ceramicstructures plus A number of properties found in metallic structures andcombine those properties in a single MAXMET structure. MAXMET compositesare characterized by excellent mechanical properties, improvedtoughness, high damage tolerance, high thermal stability and improvederosion resistance. In a structure subject to high cycle fatigue, MAXMETcomposites can suppress the propagation of cracks. All of theseproperties make them useful in aerospace applications.

Structural articles that comprise MAXMET composites, either in the formof coverings or as part of the structure itself, can better absorbmechanical energy due to their microstructural features. When a bendingforce or other stress is applied to a structural article comprising aMAXMET composite, the mechanical energy represented by the bending forceor other stress dissipates through the MAXMET composite, thereby dampingthe movement or vibration of the structural article.

The body 40 of a typical fan guide vane 34 used in a jet engine such asthat shown in FIGS. 1-3 may be about eight inches long, about fiveinches wide and about one half to ⅝ inches thick, and may be made ofaluminum. To make the body 40 even lighter, areas or pockets may bemilled out of the sides 42, 44 of the body 40. Formed aluminum coverplates may be adhered to the sides 42, 44 of the vane body 40 to coverup the milled out areas or pockets. The resulting body 40 can bend,twist and flex when subjected to the forces during operation caused bythe passage of air and adjacent rotating airfoils. The vibration canincrease to the point of failure. Damping can be applied to absorb someof the energy to prevent the vibration from increasing in amplitude.MAXMET composites may be useful for such damping purposes to absorb someof the energy that otherwise causes vibration in the fan guide vane orother structure.

For example, in a fan guide vane having milled out pockets, the pocketscan be covered up with MAXMET to give the vane its original contouredshape. Alternatively the entire fan guide vane body 40 can be covered ina cover 52 made of MAXMET as shown in FIG. 3. Another option is to coatthe fan guide vane body with a MAXMET composite.

The method of manufacturing a structural article comprising a MAXMETcomposite depends on the application. For the manufacture of structuralparts such as a fan guide vane 34 having a MAXMET cover 52 such as thatillustrated in FIGS. 2 and 3, hot pressing, hot isostatic pressing,squeeze casting or melt infiltration may be used to create a contouredcover 52 of the desired geometry. The cover 52 may be adhered to thevane body 40 or other structure in any suitable manner. The cover 52 maybe 3-4 mm thick although any suitable thickness may be achieved.

The following method may be used to make a fan guide vane cover:

Step 100: Make a porous preform comprising a MAX phase material such asThAlC.

Step 102: Submerge the preform into a bath of a molten metal such asMagnesium, allowing the molten metal to infiltrate into the pores of theMAX phase preform to achieve a fully dense MAXMET composite structure.This step may be repeated as needed.

The MAX phase material is compacted (molded) into a permanent preformstructure, and then melt infiltrated with a molten metal such as ahexagonal closed packed metal like Magnesium or Zinc or other suitablemetal like Aluminum or Nickel, to form the composite structure, such asa fan guide cover 52. The cover 52 is then bonded to the hollow aluminumvane body 40, such as by metallurgical or adhesive bonding ormechanically fastening.

Alternate manufacturing routes include forming the MAXMET cover or otherstructure from a hot formed shape or spray forming a MAXMET structure tonear net shape.

Alternatively, a fan guide vane cover 52 can be made by mixing elementalpowders of metallic phase elements with a MAX phase material, and thensintering the mixture by, for example, pressured or pressurelesssintering.

These methods for making a MAXMET composite structure may be used toform the cover 52 of a structure such as a fan guide vane 34, or alarger portion of the structure, up to and including the entirestructure, by directly molding or machining the structure from a MAXMETcomposite.

For making a fan guide vane comprising a MAXMET composite coating,numerous techniques are known, including thermal spraying and kineticdeposition of solid particles.

BENEFITS/INDUSTRIAL APPLICABILITY

The vibration damping properties of MAXMET composites through thedissipation of mechanical energy due to their non-linear elasticcharacteristics make MAXMET composites good dampener candidates.

MAXMET composites may be used to improve the overall damping, toughness,strength and erosion resistance of structures. MAXMET composites mayperform better than monolithic MAX phase materials without the metalmatrix component. The selection of magnesium based MAXMET composites(such as Mg—ThAlC) with a total composite density on the order of 2.8glee make these materials compatible with applications where aluminum iscurrently used.

What is claimed is:
 1. A turbine engine component for a gas turbineengine, the turbine engine component comprising: a body; and a dampingcover that covers part of or all of the body, wherein the part of thebody includes at least one section of the body configured to be locatedwithin airflow of the gas turbine engine; wherein the damping covercomprises a MAXMET composite, wherein the MAXMET composite is acomposite material comprising a MAX phase material and a metalcomponent, the metal component being a metal matrix.
 2. The turbineengine component of claim 1 wherein: the MAX phase material comprisesMAX phase particles having a crystalline nanolaminated structure.
 3. Theturbine engine component of claim 2 wherein: the MAX phase particles areembedded in the metal matrix.
 4. The turbine engine component of claim 3wherein: the MAX phase material has the formula M_(n+1)AX_(n), wherein Mis a transition metal; A is an A-group element; X is carbon (C),nitrogen (N) or both; and n=1 to
 3. 5. The turbine engine component ofclaim 4 wherein: the MAX phase material is selected from the groupconsisting of Ti₂AlC, Cr₂AlC, Ta₂AlC, Ti₂AIN, and Ti₄AlN₃.
 6. Theturbine engine component of claim 4 wherein: the metal componentcomprises a hexagonal closed packed metal.
 7. The turbine enginecomponent of claim 6 wherein: the hexagonal closed packed metal isselected from the group consisting of Magnesium, Titanium, Cobalt, Zinc,and Zirconium.
 8. The turbine engine component of claim 4 wherein: theMAX phase material defines a plurality of pores; and the metal componentoccupies at least some of the pores.
 9. The turbine engine component ofclaim 4 wherein: the MAX phase particles are bonded to the metal matrixby chemical or metallurgical bonding.
 10. The turbine engine componentof claim 4 wherein: the turbine engine component is an aluminum fanguide vane; and the MAXMET composite is compatible with aluminum. 11.The turbine engine component of claim 1 wherein: the damping cover is aMAXMET composite coating.
 12. The turbine engine component of claim 1wherein: the body defines areas or pockets covered by the damping cover.13. A method of making a vibration resistant turbine engine componentcomprising a body, the method comprising the steps of: Step 100: Makinga preform comprising a MAX phase material, the preform defining aplurality of pores; Step 102: Submerging the preform into a bath of amolten metal, allowing the molten metal to infiltrate into the pores ofthe preform of the MAX phase material to achieve a MAXMET composite,wherein the MAXMET composite is a composite material comprising the MAXphase material and a metal component formed from the molten metal, themetal component being a metal matrix; and Step 104: Bonding the cover topart of or all of the body, wherein the part of the body includes atleast one section of the body configured to be located within airflow ofthe gas turbine engine.
 14. The method of claim 13 wherein: Step 104comprises bonding the cover to the body by metallurgical or adhesivebonding or mechanically fastening.